101671-9850 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016719850 1671295002

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101671-9850 1016719850

NISSAN-DIESEL 1671295002 1671295002

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Service parts 101671-9850 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101067-1810

3. GOVERNOR 105400-7320

4. SUPPLY PUMP 105220-7050

5. AUTOM. ADVANCE MECHANIS 105612-3100

6. COUPLING PLATE 105661-0601

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-4030

11. Nozzle and Holder 16600-95000

12. Open Pre:MPa(Kqf/cm2) 17.7{180}

13. NOZZLE-HOLDER 105031-4260

14. NOZZLE

105015-3370

15. NOZZLE SET

Include in #1:

101671-9850 as INJECTION-PUMP ASSEMBLY

Include in #2:

104740-8550 as _

Cross reference number

ZEXEL 101671-9850 1016719850

NISSAN-DIESEL 1671295002 1671295002

Zexel num

Bosch num

Firm num

Name

101671-9850

1671295002 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
ND605 * K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8140

Bosch type code EF8511/9A

Nozzle 105780-0000

Bosch type code DN12SD12T

Nozzle holder 105780-2080

Bosch type code EF8511/9

Opening pressure MPa 17.2

Opening pressure kgf/cm2 175

Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600

Tester oil delivery pressure kPa 157 157 157

Tester oil delivery pressure kgf/cm2 1.6 1.6 1.6

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-4-2-6- 3-5

Pre-stroke mm 2.5 2.45 2.55

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5

Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 12.1

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 65.7 64.7 66.7

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 11.3+-0. 5

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 57.3 55.8 58.8

Max. variation between cylinders % 0 -4 4

Fixing the rack *

Injection quantity adjustment_03

Adjusting point -

Rack position 7.4+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 9 7.8 10.2

Max. variation between cylinders % 0 -13 13

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Timer adjustment

Pump speed r/min 300

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min 600

Advance angle deg. 1.3 0.8 1.8

Timer adjustment_03

Pump speed r/min 900

Advance angle deg. 2.9 2.4 3.4

Timer adjustment_04

Pump speed r/min -

Advance angle deg. 6 6 6

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT: RAL (3)Idle sub spring setting: L1.
----------
K=4 RAL=12.7+-0.1mm L1=7-0.5mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Set the pump speed at aa. ( At delivery ) (2)Set the pump speed at bb. (3)Stopper bolt setting
----------
aa=900r/min bb=750r/min
----------
a=(1deg)+-5deg b=(23deg)+-5deg c=(6deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=26.5deg+-5deg b=53deg+-5deg

0000001501 GOV FULL LOAD ADJUSTMENT

Title1:Full load stopper adjustment Title2:Governor set speed LABEL1:Distinguishing LABEL2:Pump speed (r/min) LABEL3:Ave. injection quantity (mm3/st) LABEL4:Max. var. bet. cyl. LABEL5:Remarks LABEL6:Distinguishing LABEL7:Governor set speed (r/min) LABEL8:Remarks (1)Adjustment conditions are the same as those for measuring injection quantity. (2)-
----------

----------
a1=B a2=- r1=750r/min r2=- Q1=65.7+-1mm3/st Q2=- c1=+-2.5% c2=- a3=18 a4=15 r3=900r/min r4=750r/min

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(30deg)

Information:

This Revised Service Letter replaces the 30May2018 Service Letter. Changes have been made to the Parts Needed.
TERMINATION DATE
31May2020
PROBLEM
The DEF injector can become plugged on certain 953K and 963K Track-Type Loaders. If the DEF injector becomes plugged it can lead to partial or full blockage of DEF flow.
AFFECTED PRODUCT
Model Identification Number
953K LJT00100-00211
963K LBL00100-00678
PARTS NEEDED
Qty
Part Number Description
1 4182073 GASKET AS
1 4609257 INJECTOR AS-DEF
1 5457669 SFWR GP-A1000
1 5460139 SFWR GP-A1000
1 BULK_COOLANT COOLANT See OMM
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 6% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
ACTION REQUIRED
DEF Injector Replacement ? Remove and Install:
Remove DEF injector and replace. Follow Disassembly and Assembly, UENR0006, for DEF Injector and Mounting - Remove and Install.
Update Engine Software:
Reflash the engine controller (ECM) with the software listed in the Parts Needed or latest available on SIS Web.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-3000 hrs,
0-36 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
3001-5000 hrs,
37-60 mo 100.0% 0.0% 0.0% 0.0% 0.0% 100.0%
This is a 1.5-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.